Color filter substrate, method of manufacturing the same, display device, liquid crystal display device and electronic equipment

ABSTRACT

Aspects of the invention can provide a color filter substrate that is suitable for being appropriately applied with a liquid color filter material, a manufacturing method thereof, a display device, a liquid crystal display device and electronic equipment. The color filter substrate can include a first layer having an opening, a reflective part, a transmissive part and a filter layer that is placed on the opening and formed to cover the reflective part and the transmissive part. The transmissive part can be an opening of the reflective part and can have a generally elliptical shape.

BACKGROUND OF THE INVENTION

1. Field of Invention

Aspects of the invention can relate to a liquid crystal display deviceand a manufacturing method thereof. More particularly, the invention canrelate to a color filter in which a single pixel area has a transmissivepart and a reflective part and a manufacturing method thereof.

2. Description of Related Art

A related manufacturing apparatus to manufacture a color filter bydischarging color filter ink drops onto a color filter substrate throughan ink-jet head is disclosed in, for example, Japanese Unexamined PatentPublication No. 10-260307.

A color filter emits only a specific wavelength light by nottransmitting light that enters into a filter layer other than thespecific wavelength light, and emits a light having a color thatcorresponds to the specific wave length. A light path length, in otherwords, a thickness of the filter layer is one of the factors that decidea characteristic of the color filter, and it is preferred that thethickness of the filter layer is even. When the color filter ismanufactured by discharging liquid color filter material drops, it ispreferred that a discharged area that is made to form the filter layeris filled up with the liquid color filter material without leaving anyunfilled area.

Further, in a case of a color filter substrate that has a reflectivepart where an outside light is reflected and a transmissive part wherean illumination light (a back light) is transmitted in a single pixel, afilter layer can be made by drying the liquid color filter material thatis filled in the transmissive part and on the reflective part. However,there is a step at the border between the transmissive part and thereflective part because the transmissive part is an opening placed inthe reflective part. A plane viewing angle of the transmissive partcorresponds to a corner of a concave, and it is difficult to fill thecorner with the liquid color filter material. Therefore, there can be aproblem that a filter which has a shape following a shape of thetransmissive part cannot be formed.

SUMMARY OF THE INVENTION

Aspects of the invention has been developed in consideration of theabove-mentioned problem, and can provide a color filter substrate thatis suitable for being appropriately applied with a liquid color filtermaterial, a manufacturing method thereof, a display device, a liquidcrystal display device and electronic equipment.

An exemplary color filter substrate of the invention can include a firstlayer having an opening, a reflective part, a transmissive part that isan opening of the reflective part and has an approximately ellipticalshape and a filter layer that is placed on the opening and formed tocover the reflective part and the transmissive part.

A method of manufacturing a color filter substrate of the invention caninclude a step for forming a reflective part and a transmissive partthat is an opening of the reflective part and has an approximatelyelliptical shape on a surface of a light transmittable member, a stepfor forming a first layer having a opening corresponding to thereflective part and the transmissive part, a step for applying a liquidcolor filter material inside the opening so as to cover the reflectivepart and the transmissive part; and a step for forming a filter layer bydrying the applied liquid color filter material.

According to the above-described structure and method, because thetransmissive part is approximately the elliptical shape, it does nothave any corners which it is difficult to be filled with the colorfilter material, and the whole of the transmissive part can be filledwith the liquid color filter material without leaving any unfilledparts.

In the color filter substrate, a second layer is preferably placed onthe first layer. Since the discharged droplet (color filter material)tends to drop into the opening of the first layer, it makes easier tomake the color filter substrate by using a discharging apparatus such asan ink-jet apparatus and the like.

In the color filter substrate, a surface of the reflective part is alight scattering surface. According to the above-mentioned structure,the color filter substrate with which the light reflected at thereflective part will not dazzle is obtained.

In the color filter substrate, a light transmittable substrate and aresin layer placed on the substrate and having a patterned indentedsurface are preferably included. And the reflective part can be formedon the patterned indented surface, such that the surface of thereflective part becomes the light scattering surface.

According to the above-mentioned structure, the light scattering surfacecan be easily formed on the surface of the reflective part.

In the color filter substrate, a water-shedding quality of the secondlayer against a liquid color filter material of the filter layer ispreferably higher than that of the first layer. According toabove-mentioned structure, when the color filter material is dischargedfrom a discharging apparatus, such as an ink-jet apparatus, because thedischarged color filter material hardly goes beyond the second layer, itdoes not flow out of the opening of the first layer and flows into theinside the opening. Consequently, application of the color filtermaterial can be easily performed.

In the color filter substrate, the first layer preferably shows alyophilic quality to the liquid color filter material. According toabove-mentioned aspect, more even layer of the color filter material isformed within the opening of the first layer.

In the color filter substrate, the second layer is preferably a resistto pattern the first layer. According to above-mentioned structure, aprocess in which the resist is removed in order to form the second layerafter the first layer is formed is not needed. As a result, amanufacturing time is shortened.

In the color filter substrate, more preferably, the resist can include afluorinated polymer. According to above-mentioned structure, the resistshows a water-shedding quality to the color filter material withoutperforming a surface quality modification process. Therefore, a plasmatreatment is not necessary to be performed and it leads to shorten themanufacturing time.

In the color filter substrate, the first layer can preferably be a blackmatrix. According to above-mentioned structure, since light is obscuredby the black matrix and it does not pass through a plurality of openingsthat are defined by the black matrix, it can prevent color mixture amongpixels.

In the color filter substrate, an overcoat layer may be placed on thereflective part. And the filter layer covers the overcoat layer and thetransmissive part. According to above-mentioned structure, a colorpurity of a reflected light can be lowered, and a difference between thecolor purity of a reflected light and a color purity of a transmittedlight is made to be small. Consequently, a color appearance of a displayusing the reflected light and a color appearance of a display using thetransmitted light are conformed.

The invention can be realized in various forms, such as a display havingthe above-described color filter substrate, a liquid crystal displaydevice having a light source member, a liquid crystal layer and thecolor filter substrate placed between the light source member and theliquid crystal layer and electronic equipment having such liquid crystaldisplay device.

In this specification, the display device can include a plasma displaydevice, a liquid crystal display device, an electro-luminescence displaydevice, a display device using an electron emission element, such as afield emission display (FED) and a surface conduction electron emitterdisplay (SED), and the like.

BRIEF DESCRIPTION OF THE DRAWINGS

This invention will be described with reference to the accompanyingdrawings, wherein like numerals reference like elements, and wherein:

FIGS. 1( a) and (b) show a frame format of a liquid crystal displaydevice of a first exemplary embodiment;

FIG. 2 is a view showing a frame format of a manufacturing apparatus ofthe first exemplary embodiment;

FIG. 3 is a view showing a frame format of a discharging apparatus;

FIG. 4 is a view showing a frame format of a carriage of the firstexemplary embodiment;

FIG. 5 is a view showing a frame format of a head of the first exemplaryembodiment;

FIGS. 6( a) and (b) show a frame format of a discharging member in thehead of the FIG. 5;

FIG. 7 is a functional block diagram of a control member in thedischarging apparatus;

FIGS. 8( a) through (d) show a frame format of a manufacturing methodfor a base substrate of the first exemplary embodiment;

FIG. 9 is a view showing a frame format of a discharged portion of thefirst exemplary embodiment;

FIG. 10 is a view showing a frame format of a discharging method of thefirst exemplary embodiment;

FIG. 11 is a view showing a frame format of the discharging method ofthe first exemplary embodiment;

FIGS. 12( a) through (d) shows a frame format of the discharging methodof the first exemplary embodiment;

FIG. 13 is a view showing a frame format of a scan field of the firstexemplary embodiment;

FIGS. 14( a) through (d) shows a frame format of a manufacturing methodof the first exemplary embodiment;

FIG. 15 shows a frame format of a liquid crystal display device of asecond exemplary embodiment;

FIGS. 16( a) through (e) show a frame format of a manufacturing methodfor a base substrate of the second exemplary embodiment;

FIGS. 17( a) through (d) shows a frame format of a discharging method ofthe second exemplary embodiment;

FIG. 18 is a view showing a frame format of a cellular phone of a thirdexemplary embodiment;

FIG. 19 is a view showing a frame format of a wristwatch type electronicequipment of the third exemplary embodiment;

FIG. 20 is a view showing a frame format of a portable informationprocessor of the third exemplary embodiment; and

FIGS. 21( a) and (b) show a frame format of a shape of a transmissivepart.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Taking a case in which the invention is applied to a liquid crystaldisplay device for example, the invention is described below withreference to figures. Exemplary embodiments described below shall notlimit an invention which is described in claims. Also, all of componentsdescribed in the embodiments below are not always essential as asolution for the invention described in claims.

A liquid crystal display device 11 shown in FIG. 1 is a display having atwo-terminal element Thin Film Diode (TFD) as a switching element. Theliquid crystal display device 11 has a polarization plate 20A, apolarization plate 20B, a color filter substrate 10, a counter substrate12, a liquid crystal layer 14 and a light source member 16. The liquidcrystal layer 14 is placed between the color filter substrate 10 and thecounter substrate 12. The color filter substrate 10 is placed betweenthe liquid crystal layer 14 and the light source member 16. The colorfilter substrate 10, the liquid crystal layer 14 and the countersubstrate 12 are located between the polarization plate 20A and thepolarization plate 20B.

The color filter substrate 10 can include a light transmittablesubstrate 32, a reflective part 26, a transmissive part 28, and filterlayers 111FR, 111FG and 111FB that are provided in the plural number.The color filter substrate 10 also includes a black matrix 17, a bank30, a planarizing layer 34, a light transmittable electrode 36 that isprovided in the plural number and an alignment film 38A. In thisexemplary embodiment, the substrate 32 is located between thepolarization plate 20A and the reflective part 26 or the transmissivepart 28. The light transmittable substrate 32 is an example of a lighttransmittable member of the invention.

The polarization plate 20A is placed to nearly cover the whole surfaceof the substrate 32. In this exemplary embodiment, though thepolarization plate 20A contacts with the substrate 32, the polarizationplate 20A and the substrate 32 can be separated.

Both the reflective part 26 and the transmissive part 28 are located onthe substrate 32. Both the reflective part 26 and the transmissive part28 are placed in an area corresponding to each of filter layers 111FR,111FG and 111FB. In this exemplary embodiment, the reflective part 26and the transmissive part 28 are an aluminum film formed on thesubstrate 32 and its opening part, respectively.

The black matrix 17 has an opening 17A that is provided in the pluralnumber. To be more specific, the black matrix 17 is a light shieldingpart that has a shape defining the opening 17A. A plurality of theopenings 17A are provided in matrix and each opening 17A corresponds toa pixel region G that is described later. The black matrix 17 is formedon an each part of the reflective part 26. The black matrix 17 is anexample of a first layer of the invention.

Each of the filter layers 111FR, 111FG and 111FB corresponds to one ofthree colors. In particular, the filter layer 111FR corresponds to red,the filter layer 111FG corresponds to green and the filter layer 111FBcorresponds to blue. Each of the filter layers 111FR, 111FG and 111FB islocated each of openings 17A respectively.

The bank 30 is formed on the black matrix 17. A planar shape of the bank30 is the same planar shape of the black matrix 17. As described indetail later, a water-shedding quality of the bank 30 against the liquidcolor filter material for forming the filter layers 111FR, 111FG and111FB is higher than that of the black matrix 17 against the colorfilter material. The bank 30 is an example of a second layer of theinvention.

The planarizing layer 34 is located to cover the filter layers 111FR,111FG and 111FB and the bank 30. To be more specific, the planarizinglayer 34 covers a step formed by the filter layers 111FR, 111FG and111FB and the bank 30 so as to obtain a substantially flat surface. Aplurality of electrodes 36 can be located on the planarizing layer 34.Each electrode 36 has a stripe shape that extends in a Y-axis direction(direction perpendicular to the page of FIG. 1( a)) and the electroderuns parallel each other. The alignment film 38A is placed to cover theplurality of electrodes 36 and the planarizing layer 34, and a rubbingtreatment in a certain direction is performed.

The counter substrate 12 includes a light transmittable substrate 40 anda light transmittable electrode 42 that can be provided in the pluralnumber and an alignment film 38B. The substrate 40 is located betweenthe polarization plate 20B and the electrodes 42. The polarization plate20B is placed to nearly cover the whole surface of the substrate 40. Inthis embodiment, though the polarization plate 20B contacts with thesubstrate 40, the polarization plate 20B and the substrate 40 can beseparated. Though it is not shown in FIG. 1, the counter substrate 12has a two-terminal element that is electrically coupled to the electrode42 and provided in a plural number.

A plurality of the electrodes 42 can be provided in matrix. Thealignment film 38B is placed to cover the plurality of electrodes 42 andthe substrate 40, and a rubbing treatment in a certain direction isperformed. In this exemplary embodiment, the rubbing direction of thealignment film 38B and that of the alignment film 38A are set such thata liquid crystal is aligned in a Twisted Nematic (TN) alignment betweenthe alignment film 38A and the alignment film 38B.

The liquid crystal layer 14 can be placed between the color filtersubstrate 10 and the counter substrate 12. In particular, the liquidcrystal layer 14 is located in a space that is secured by spacersprovided between the alignment film 38A and the alignment film 38B, andcontacts with the alignment film 38A and the alignment film 38B.

A part where the electrode 36 overlaps the electrode 42 corresponds tothe pixel region G.

The single pixel region G also means a region where corresponds one ofthe filter layers 111FR, 111FG and 111FB.

The light source member 16 is provided in a way that the color filtersubstrate 10 is located between the light source member 16 and theliquid crystal layer 14. The light source member 16 of this embodimentis also called as a back light. The light source member 16 includes alight source 16A that emits a white light and a light guide member 16B.The light guide member 16B guides a light from light source 16A asdiffusing it so as to evenly illuminate the substrate 32 from its backsurface. The back surface of the substrate 32 is the opposite surface toa surface on which the filter layers 111FR, 111FG and 111FB, the blackmatrix 17, the reflective part 26 and the transmissive part 28. For thisreason, for example, the position of the substrate 32 can be describedas it is located between the filter layers 111FR, 111FG and 111FB andthe light source member 16.

As described above, in the color filter substrate 10, the reflectivepart 26 and the transmissive part 28 are located corresponding to eachof the filter layers 111FR, 111FG and 111FB. The liquid crystal displaydevice 11 having such color filter substrate 10 works as describedbelow.

When the back light (the light source member 16) is used, a light beam Pfrom the back light travels through the polarization plate 20A and thesubstrate 32, and then passes through the transmissive part 28. Thelight beam passed through the transmissive part 28 enters into thefilter layers 111FR, 111FG and 111FB, and then a light beam that has acorrespondent wave length band is emitted from the filter layers 111FR,111FG and 111FB. The light beam (a colored light) form the filter layers111FR, 111FG and 111FB travels through the liquid crystal layer 14 andthe counter substrate 12, and then it is emitted from the polarizationplate 20B. At an emitting area of the polarization plate 20B, anintensity of the light beam form the back light is modulated accordingto a voltage applied between the electrode 36 and the electrode 42.

On the other hand, when outside light is used, a light beam S includingthe outside light travels through the polarization plate 20B and thecounter substrate 12 and the liquid crystal layer 14, and enters intothe corresponding filter layers 111FR, 111FG and 111FB. Out of the lightbeam traveled through the filter layers 111FR, 111FG and 111FB, a lightbeam that is reflected by the reflective part 26 passes again throughthe filter layers 111FR, 111FG and 111FB and then emitted as acorrespondent colored light. Each of colored light again travels throughthe liquid crystal layer 14 and the counter substrate 12, and then it isemitted from the polarization plate 20B. At an emitting area of thepolarization plate 20B, an intensity of the light beam including theoutside light is modulated according to the voltage applied between theelectrode 36 and the electrode 42.

With the above-described structure, a first light beam that enters forma first side of the black matrix 17 and travels through thecorrespondent filter layers 111FR, 111FG and 111FB is reflected to thefirst side by the reflective part 26. On the other hand, a second lightbeam that enters form a second side of the black matrix 17 is emitted tothe first side through the transmissive part 28 and the correspondentfilter layers 111FR, 111FG and 111FB. The first side of the black matrix17 can mean a side on which the planarizing layer 34 and the liquidcrystal layer 14 are located. In contrast, the second side of the blackmatrix 17 means a side on which the light source member 16 is located.

In this way, the liquid crystal display device 11 can display imagesmaking use of both the outside light and the light from the back light.The liquid crystal display device 11 having such function is called atransflective display device.

The filter layers 111FR, 111FG and 111FB in the color filter substrate10 are formed by discharging the color filter material in the opening17A of the black matrix 17 from a discharging apparatus, such as anink-jet apparatus and the like.

In this embodiment, the color filter substrate 10 in which the filterlayers 111FR, 111FG and 111FB have not been provided yet may be referredas a base substrate 10A. Also, in this exemplary embodiment, regionswhere each of filter layers 111FR, 111FG and 111FB are formed may bereferred as discharged portions 18R, 18G and 18B, respectively.According to this description, in this embodiment, each concave portionwhich is surrounded by the bank 30, the black matrix 17, the reflectivepart 26 and the transmissive part 28 corresponds to each of thedischarged portions 18R, 18G and 18B in the base substrate 10A.

In what follows, a manufacturing apparatus for manufacturing the liquidcrystal display device 11 is described.

A manufacturing apparatus 1 shown in FIG. 2 is an apparatus to dischargea correspondent color filter material to each of discharged portions18R, 18G and 18B of the base substrate 10A. To be more specific, themanufacturing apparatus 1 has a discharging device 100R that applies acolor filter material 111R to the all discharged portions 18R and adrying device 150R that dries the color filter material 111R on thedischarged portion 18R. The manufacturing apparatus 1 also has adischarging device 100G that applies a color filter material 111G to theall discharged portions 18G, a drying device 150G that dries the colorfilter material 111G on the discharged portion 18G, a discharging device100B that applies a color filter material 111B to the all dischargedportions 18B and a drying device 150B that dries the color filtermaterial 111B on the discharged portion 18B. The manufacturing apparatus1 further has an oven 160 in which the color filter materials 111R, 111Gand 111B are heated again (post-bake), a discharging device 100C to formthe planarizing layer 34 on a layer of post-baked color filter materials111R, 111G and 111B, a drying device 150C that dries the planarizinglayer 34 and a curing device 165 that heats the dried planarizing layer34 again and hardens it. Further, the manufacturing apparatus 1 includesa carrier device 170 that carries the base substrate 10A to thedischarging device 100R, the drying device 150R, the discharging device100G, the drying device 150G, the discharging device 100B, the dryingdevice 150B, the discharging device 100C, the drying device 150C and thecuring device 165, in this order.

As shown in FIG. 3, the discharging device 100R includes a tank 101Rwhere the liquid color filter material 111R is stored and a dischargingand scanning part 102 into which the color filter material 111R isprovided from the tank 101R through a tube 110R. The discharging andscanning part 102 includes a carriage 103 that has a head 114 (FIG. 4)which can discharge the color filter material and is provided in aplural number and a first positioning control device 104 that controlsthe position of the carriage 103. The discharging and scanning part 102also includes a stage 106 that holds the base substrate 10A, a secondpositioning control device 108 that controls the position of the stage106 and a control member 112. The tank 101R and the heads 114 in thecarriage 103 are coupled with the tube 110R, and the liquid color filtermaterial 111R is provided to each of the heads 114 from the tank 101R bya pressure which is caused by a level difference between a liquid levelof the color filter material 111R in the tank 101R and a level of anozzle of a nozzle plate 128 which is described below.

The liquid color filter material 111R of this embodiment is an exampleof a liquid material of the invention. The liquid material means amaterial having a viscosity with which the material can be dischargedfrom the nozzle. In this case, the material can be both water-based andoil-based material. It is enough to have liquidity (the viscosity) withwhich the material can be discharged from the nozzle, and it can evencontains a solid matter as long as it can be taken as fluid as a whole.

The first positioning control device 104 has a linear motor and movesthe carriage 103 along a X-axis direction and a Z-axis direction that isorthogonal to the X-axis direction according to a signal from thecontrol member 112. The second positioning control device 108 has thelinear motor and moves the stage 106 along a Y-axis direction that isorthogonal to the X-axis direction and the Z-axis direction according toa signal from the control member 112. The stage 106 has a plane that isparallel to both X-axis direction and the Y-axis direction, and the basesubstrate 10A is fixed on the plane. Since the stage 106 fixes the basesubstrate 10A, the stage 106 can decide the positions of the dischargedportions 18R, 18G and 18B. The base substrate 10A of this exemplaryembodiment is an example of a receiving substrate.

The first positioning control device 104 further has a function rotatingthe carriage 103 around a certain axis that is parallel to the Z-axisdirection. The Z-axis direction refers a direction that is parallel tovertical direction (in other words, a direction of gravitationalacceleration). An X-axis and a Y-axis in a coordinate system that isfixed on the receiving substrate can be parallelized to the X-axisdirection and the Y-axis direction respectively by rotating the carriage103 around the certain axis that is parallel to the Z-axis direction bythe first positioning control device 104. In this exemplary embodiment,the X-axis direction and the Y-axis direction are directions in whichthe carriage moves relatively to the stage 106. In this specification,the first positioning control device 104 and the second positioningcontrol device 108 may be referred as a scan unit.

The carriage 103 and the stage 106 further have a freedom degree ofparallel transition and rotation other than the above-described ones.However, in this exemplary embodiment other freedom degree is notdescribed in order to simplify the explanation.

The control member 112 is formed to accept a discharge data showing arelative position where the color filter material 111R should bedischarged from an outside information processor. Detailed function ofthe control member 112 is described later.

As shown in FIG. 4, the carriage 103 has the head 114 that is providedin the plural number and each head has the same structure. Here, FIG. 4is a view of the carriage 103 that is looked from a side of the stage106. Therefore, the orthogonal direction to the figure is the Z-axisdirection. In this exemplary embodiment, six heads 114 consists a lineand the two lines are provided in the carriage 103. Also, each head 114is fixed in the carriage 103 such that a long side of the head 114 isplaced at an angle AN to the X-axis direction.

As shown in FIG. 5, the head 114 for discharging the color filtermaterial 111R has two of a nozzle line 116 that extends in the long sidedirection of the head 114. The nozzle line 116 is a line in which 180 ofnozzles 118 align. A distance between the nozzles 118 along a nozzleline direction HX is about 140 μm. In FIG. 5, the two nozzle lines 116of the single head 114 are placed in a half pitch (about 70 μm) aparteach other. Further, a diameter of the nozzle 118 is approximately 27μm.

As described above, since the long side of the head 114 is placed at theangle AN to the X-axis direction, the nozzle line direction HX, in otherwords, a direction in which 180 nozzles 118 align is also placed at theangle AN to the X-axis direction. An edge of each nozzle 118 is locatedon a hypothetical plane that is defined by the above-described X-axisdirection and the Y-axis direction. A shape of each nozzle 118 isadjusted such that the head 114 can discharge the material approximatelyparallel to the Z-axis.

The angle AN may be set in such a way as at least any two nozzlessimultaneously correspond to some of the discharged portions 18R thatalign in the X-axis direction. In this way, two lines can be scanned andapplied together in one scanning period. In this case, any two nozzles118 may not be adjacent to each other.

As shown in FIG. 6( a) and FIG. 6( b), each head 114 is an ink-jet head.More particularly, each head 114 has a vibrating board 126 and a nozzleplate 128. A store 129 is provided between the vibrating board 126 andthe nozzle plate 128. The store 129 is always filled with the colorfilter material 111R that is provided from the tank 101R through anopening 131. A dividing wall 122 is located between the vibrating board126 and the nozzle plate 128. The dividing wall 122 is provided in aplural number. And a part that is surrounded by the vibrating board 126,the nozzle plate 128 and a pair of the dividing walls 122 is a cavity120. The number of the cavity 120 and the number of the nozzle 118 aresame because the cavity 120 is provided corresponding to the nozzle 118.The color filter material 111R is provided into the cavity 120 from thestore 129 through a feed opening 130 that is located between the pair ofthe dividing walls 122.

An oscillator 124 is provided on the vibrating board 126 correspondingto each cavity 120 and in a plural number. The oscillator 124 includes apiezoelectric element 124C, a pair of electrodes 124A and 124B thatsandwiches the piezoelectric element 124C. The liquid color filtermaterial 111R is discharged form the correspondent nozzle by applyingthe driving voltage to the pair of electrodes 124A and 124B.

The control member 112 (FIG. 3) is made to provide an independent signalto each of the oscillators 124. Therefore, a volume of the color filtermaterial 111R that is discharged form the nozzle 118 is controlled byeach nozzle 118 corresponding to the signal from the control member 112.Further, the volume of the color filter material 111R that is dischargedform each nozzle 118 can be changed within a range of 0-42 pl(pico-liter). Therefore, a nozzle 118 that discharges during the scanand the application and a nozzle 118 that does not discharge may be set.

In this specification, a part that includes the one nozzle 118, thecavity 120 corresponding to the nozzle 118 and the oscillator 124corresponding to the cavity may be referred as a discharging member 127.

According to such description, the one head 114 has the same number ofthe discharging member 127 as that of the nozzle 118. Instead of thepiezoelectric element, the discharging member 127 may have anelectrothermal converting element. In other words, the dischargingmember may have a structure in which the material is discharged makinguse of a thermal expansion of the material with the electrothermalconverting element.

As described above, the carriage 103 is moved in the X-axis directionand the Z-axis direction by the first positioning control device 104(FIG. 3). On the other hand, the stage 106 (FIG. 3) is moved in theY-axis direction by the second positioning control device 108 (FIG. 3).Consequently, the relative position of the head 114 against the stage106 is changed by the first positioning control device 104 and thesecond positioning control device 108. To be more specific, the heads114, the nozzle lines 116 and the nozzles 118 are relatively moved andscan in the X-axis direction and the Y-axis direction as they keep acertain distance from the discharged portions 18R that is fixed on thestage 106 in the Z-axis direction. More particularly, the head 114discharges the material from the nozzles 118 as it relatively scans tothe stage in the X-axis direction and the Y-axis direction. In thepresent invention, the nozzle 118 can scan the discharged portion 18Rand the material can be discharged from the nozzle 118 onto thedischarged portion 18R. A relative scan includes that one of adischarging side and a side at which the discharged material arrives(the discharged side 18R) is at least moved and scans the other side.Also, a combination of the relative scan and the discharge of thematerial may be referred as discharging scan.

Next, a structure of the control member 112 is described. As shown inFIG. 7, the control member 112 has an input buffer memory 200, a memorydevice 202, a processing member 204, a scan driver 206 and a head driver208. The input buffer memory 200 and the processing member 204 arecoupled so as to communicate each other. The processing member 204 andthe memory device 202 are coupled so as to communicate each other. Theprocessing member 204 and the scan driver 206 are coupled so as tocommunicate each other. The processing member 204 and the head driver208 are coupled so as to communicate each other. Also, the scan driver206 is coupled to the first positioning control device 104 and thesecond positioning control device 108 so as to communicate each other.The head driver 208 is also coupled to each of heads 114 so as tocommunicate each other.

The input buffer memory 200 receives the discharge data for dischargingthe color filter material 111R from the outside information processor.The discharge data includes a data that shows relative positions of allthe discharged portions 18R on the base substrate 10A and a data thatshows a position where the material should be discharged or where thematerial should arrive. The discharge data also includes a data thatshows a number of the relative scan which is required to apply the colorfilter material 111R in an intended thickness on all the dischargedportions 18R and a data that specifies which nozzle to discharge thematerial and which nozzle to halt the discharging. The input buffermemory 200 provides the discharge data to the processing member 204. Theprocessing member 204 stores the discharge data in the memory device202. In FIG. 7, the memory means 202 is a random access memory (RAM).

The processing member 204 provides the scan driver 206 with a data thatshows a relative position of the nozzle line 116 to the dischargedportions 18R, based on the discharge data in the memory device 202. Thescan driver 206 provides a driving signal according to this data to thefirst positioning control device 104 and the second positioning controldevice 108. Consequently, the nozzle line 116 is relatively movedagainst the discharged portions 18R. On the other hand, the processingmember 204 provides the head driver 208 with a data that shows a timingof discharging from the correspondent nozzle 118, based on the dischargedata stored in the memory device 202. Based on this data, the headdriver 208 gives a driving signal which is necessary to discharge thecolor filter material 111R to the head 114. Accordingly, the liquidcolor filter material 111R is discharged form the corresponding nozzle118 in the nozzle line 116.

The control member 112 may be a computer including a central processingunit (CPU), a read only memory (ROM) and a random access memory (RAM).In this case, the above-described function of the control member 112 isrealized with a software program executed by computer. As a matter ofcourse, the control member 112 can be made up with a special circuit(hardware).

With the above-described structure, the discharging device 100R scansand applies the color filter material 111R according to the dischargedata given to the control member 112.

The above-mentioned description is the explanation for the structure ofthe discharging device 100R. The structure of the discharging device100G, the structure of the discharging device 100B and the structure ofthe discharging device 100C are essentially same as that of thedischarging device 100R. Except the discharging device 100G is differentform the discharging device 100R in that it has a tank for the colorfilter material 111G instead of the tank 101R of the discharging device100R. In a similar way, the discharging device 100B is different formthe discharging device 100R in that it has a tank for the color filtermaterial 111B instead of the tank 101R. Furthermore, the dischargingdevice 100C is different form the discharging device 100R in that it hasa tank for a protective film material instead of the tank 101R.

Next, a manufacturing method for the liquid crystal display device 11 isdescribed.

Firstly, the reflective part 26 and the transmissive part 28 which isthe opening in the reflective part 26 are formed on a surface of a lighttransmittable material. More particularly, as shown in FIG. 8( a), analuminum (Al) film is formed on the light transmittable substrate 32such as a glass substrate so as to almost cover the whole surface of thesubstrate by sputtering and the like. Here, the substrate 32 correspondsto the light transmittable member. Then, as shown in FIG. 8( b), the Alfilm is patterned so as to form the reflective part 26 and thetransmissive part 28 in each pixel region G. To be more specific, the Alfilm is patterned in such a way that a shape of the transmissive part 28becomes approximately an elliptical shape. A remaining Al film on thesubstrate 32 is the reflective part 26 and an area where the Al film isremoved is the transmissive part 28 after the patterning. In this way,the reflective part 26 and the transmissive part 28 which is the openingin the reflective part 26 are formed on the surface of the lighttransmittable material.

In this exemplary embodiment, as shown in detail in FIG. 21( b), a planeview shape of the transmissive part 28 is approximately the ellipticalshape when the transmissive part 28 is located on a virtual plane thatis parallel to the X-axis direction and the Y-axis direction. Moreparticularly, the transmissive part 28 is made to be approximately theelliptical shape (a track shape) which is consisted of a pair ofstraight lines and a pair of semicircles by patterning the Al film. Theelliptical shape in this specification includes not only ellipse butalso the track shape and an oval shape. As mentioned before, the X-axisdirection and the Y-axis direction are the direction in which the nozzle118 moves relatively to the discharged portion.

In this exemplary embodiment, the reflective part 26 is directly formedon the substrate 32. However, other layer such as a protective film maybe formed between the substrate 32 and the reflective part 26. In thisspecification, the substrate 32 may include such layer as the protectionfilm.

Next, a first material layer is formed so as to cover the reflectivepart 26 and the transmissive part 28. To be more specific, as shown inFIG. 8( c), a thermosetting acrylic resin in which black pigments arediffused (resin black) is applied in 3 μm thick to cover the reflectivepart 26 and the substrate 32. As a result, a resin black layer 17′ isobtained. Here, the resin black layer 17′ is an example of theabove-mentioned first material layer.

Then, a second material layer is formed by applying resist on the firstmaterial layer. More particularly, as shown in FIG. 8( c), a negativeacrylic chemical amplification type photosensitive resist in which afluorinated polymer is blended is applied to cover the whole surface ofthe resin black layer 17′.

Consequently, a resist layer 30′ is obtained on the resin black layer17′. Here, the resist layer 30′ is an example of the above-mentioned“second material layer.”

Next, the resist layer 30′ and the resin black layer 17′ are patterned.To be more specific, the resist layer 30′ is exposed to a light hvthrough a photomask that has a light shielding part corresponding towhere the pixel region G is. Then, unexposed parts to the light hv, inother words, many parts of the resist layer 30′ and the resin blacklayer 17′ corresponding to where a plurality of the pixel regions G are,are removed by etching with a certain etchant. In this way, the bank 30and the black matrix 17 that have a shape surrounding the filter layerwhich should be formed later are obtained at the same time as shown inFIG. 8( d). Stated another way, the opening 17A corresponding to thereflective part 26 and the transmissive part 28 is obtained.

As described above, areas which are surrounded or defined by the blackmatrix 17, the bank 30, the reflective part 26 and the transmissive part28 are the discharged portions 18R, 18G and 18B. The bank 30 is lighttransmissible. Also, as mentioned above, the black matrix 17 is anexample of a first layer of the invention, and the bank 30 is an exampleof a second layer of the invention.

In this manner, the area that is defined by the black matrix 17 and thebank 30 (in other words, the discharged portions 18R, 18G and 18B) isprovided on the base substrate 10A by forming the black matrix 17 andthe bank 30 located on the black matrix 17.

Next, a discharge method in which the discharging device 100R dischargesthe color filter material 111R on the discharged portions 18R isdescribed.

In the base substrate 10A shown in FIG. 9, rows and columns of thematrix which is consisted of the plurality of the discharged portions18R, 18G and 18B are parallel to the X-axis direction and the Y-axisdirection respectively. More particularly, the discharged portions 18R,the discharged portions 18G and the discharged portions 18B periodicallyalign in the X-axis direction in this order. In contrast, the dischargedportions 18R align in the Y-axis direction at regular intervals, thedischarged portions 18G align in the Y-axis direction at regularintervals and the discharged portions 18B align in the Y-axis directionat regular intervals.

An interval LRX between two discharged portions 18R along the X-axisdirection is approximately 237 μm. The interval LRX is the same as aninterval LGX between two discharged portions 18G along the X-axisdirection and an interval LBX between two discharged portions 18B alongthe X-axis direction. Also, X-axis lengths and Y-axis lengths of eachdischarged portions 18R, 18G and 18B are approximately 50 μm and 120 μm,respectively.

In this exemplary embodiment, in the discharged portion 18R, thetransmissive part 28 is dented compared with the reflective part 26 andwhich forms the step in the discharged portion 18R (FIG. 8( d)). Moreparticularly, the step is located at the border between the reflectivepart 26 and the transmissive part 28. This is because the transmissivepart 28 is the opening of the reflective part 26 and formed by removingthe part of the reflective part 26. Therefore, a size of the step isrelevant to a thickness of the reflective part 26. In the dischargedportions 18G and 18B, the transmissive part 28 is similarly dentedcompared with the reflective part 26.

For a start, the carrier device 170 positions the base substrate 10A onthe stage 106 of the discharging device 100R. To be more specific, it isfixed such as the rows and the columns of the matrix which is consistedof the plurality of the discharged portions 18R, 18G and 18B becomeparallel to the X-axis direction and the Y-axis direction.

Before a first scanning period starts, the discharging device 100Rbrings an x-coordinate of the nozzles 118 into line with an x-coordinateof the discharged portions 18R. More particularly, an x-coordinate ofthe most left nozzle 118 of the nozzles 118 shown in FIG. 10 is broughtinto line with an x-coordinate X1 of the most left discharged portion18R of the discharged portions 18R shown in FIG. 10. At the same time,an x-coordinate of the most right nozzle 118 of the nozzles 118 shown inFIG. 10 is brought into line with an x-coordinate X2 of the most rightdischarged portion 18R of the discharged portions 18R shown in FIG. 10.Hereinafter, the nozzle 118 that corresponds to the discharged portions18R can be written as a first nozzle 118A. Also, the nozzle 118 thatdoes not correspond to the discharged portions 18R can be written as asecond nozzle 118B.

In this exemplary embodiment, the scanning period can mean a period inwhich an one side of the carriage 103 moves relatively once along theY-axis direction from one end E1 (or the other end E2) of a scan field134 to the other end E2 (or the one end E1) of the scan field 134 inorder to apply the material on all the discharged portions 18R thatalign in the Y-axis direction, as shown in FIG. 13. In addition, in thisembodiment, the scan field 134 can mean an area where the one side ofthe carriage 103 moves to apply the color filter material 111R on allthe discharged portions 18R included in a matrix 18M. However, in somecases, the word scan field can refer an area where one nozzle 118 movesrelatively, an area where one nozzle line 116 moves relatively or anarea where one head 114 moves relatively. The matrix 18M is a matrixwhich the discharged portions 18R, 18G and 18B consist.

The carriage 103, the head 114 or the nozzle 118 moves relatively meansthat these relative position change against the discharged portions 18R.Therefore, even when the carriage 103, the head 114 or the nozzle 118absolutely remains stationary and only the discharged portions 18R moveby the stage 106, this is described as the carriage 103, the head 114 orthe nozzle 118 moves relatively.

As shown in FIG. 10, when the first scanning period starts, the one sideof the carriage 103 starts to move relatively from the one end E1 of thescan field 134 to an positive direction of the Y-axis (upward in thefigure). Then, during the first scanning period, when the first nozzle118A moves into a region that corresponds to the discharged portion 18R,the color filter material 111R is discharged to the correspondentdischarged portion 18R from the first nozzle 118A. To be more specific,when the first nozzle 118A moves into a region that corresponds to thetransmissive part 28 in the discharged portion 18R, the nozzle 118Adischarges the color filter material 111R. In an example shown in FIG.10, during the first scanning period, the color filter material 111R isdischarge once to each discharged portion 18R. In FIG. 10, a positionwhere the nozzle 118A discharges the color filter material 111R or alanding position BD is indicated by a black circle.

As shown in FIG. 11, when a second scanning period that consecutivelyfollows after the first scanning period starts, the carriage 103 startsto move relatively from the other end E2 of the scan field 134 to annegative direction of the Y-axis (downward in the figure). Then, duringthe second scanning period, when the first nozzle 118A moves into aregion that corresponds to the discharged portion 18R, the color filtermaterial 111R is discharged to the correspondent discharged portion 18Rfrom the first nozzle 118A. To be more specific, when the first nozzle118A moves into a region that corresponds to the reflective part 26 inthe discharged portion 18R, the nozzle 118A discharges the color filtermaterial 111R. In an example shown in FIG. 11, during the secondscanning period, the color filter material 111R is discharge twice toeach discharged portion 18R. In FIG. 11, a position where the nozzle118A discharges the color filter material 111R or a landing position BDis indicated by a black circle. The position where the color filtermaterial 111R was discharged during the first scanning period is alsoindicated by a white circle in FIG. 11.

Then, the discharging device 100R moves an x-coordinate of the carriage103 step by step and discharges the color filter material 111R to allthe discharged portions 18R in the base substrate 10A in theabove-described way.

Focusing only on a single discharged portion 18R, the above dischargingmethod is described with reference to FIG. 12.

FIG. 12 is a Y-Z cross-section view of the discharged portion 18R. Ahorizontal direction of the page of FIG. 12 is a long side of thedischarged portion 18R. As shown in FIG. 12( a), the color filtermaterial 111R is discharged to the transmissive part 28 during the firstscanning period. As shown in FIG. 12( b), when the color filter material111R arrives at the transmissive part 28, the color filter material 111Rspreads to cover not only the transmissive part 28 but also the steplocating at the border between the reflective part 26 and thetransmissive part 28. During the second scanning period, the colorfilter material 111R is discharged to the area that approximatelycorresponds to the reflective part 26 as shown in FIG. 12( c). In thiscase, some droplet of the color filter material 111R may arrive tooverlap the transmissive part 28. Then, as shown in FIG. 12( d), asolvent is evaporated from the color filter material 111R that isdischarged during the first scanning period and the second scanningperiod, and a layer of the color filter material 111R is formed in thedischarged portion 18R. The layer shown in FIG. 12( d) is further dried,and then the filter layer 111FR is obtained.

The above-mentioned description is the explanation of the dischargemethod in which the discharging device 100R discharges the color filtermaterial 111R to the discharged portion 18R. Hereinafter, a series ofmanufacturing method in which the color filter substrate 10 ismanufactured by the manufacturing apparatus 1.

The base substrate 10A on which the discharged portions 18R, 18G and 18Bare formed is carried by the carrier device 170 to the stage 106 of thedischarging device 100R. Then, as shown in FIG. 14( a), the dischargingdevice 100R discharges the color filter material 111R from thedischarging member 127 in the head 114 so as to form the layer of thecolor filter material 111R on all the discharged portions 18R. A methodin which the discharging device 100R discharges the color filtermaterial 111R is the same as the way described above with reference toFIGS. 10, 11 and 12. After the layer of the color filter material 111Ris formed on all the discharged portions 18R of the base substrate 10A,the carrier device 170 puts the base substrate 10A within the dryingdevice 150R. Then, the filter layer 111FR is obtained on the dischargedportions 18R by completely drying the color filter material 111R on thedischarged portions 18R.

Next, the carrier device 170 puts the base substrate 10A on the stage106 of the discharging device 100G. Then, as shown in FIG. 14( b), thedischarging device 100G discharges the color filter material 111G fromthe discharging member 127 in the head 114 so as to form the layer ofthe color filter material 111G on all the discharged portions 18G. Amethod in which the discharging device 100G discharges the color filtermaterial 111G is the same as the way described above with reference toFIGS. 10, 11 and 12. After the layer of the color filter material 111Gis formed on all the discharged portions 18G of the base substrate 10A,the carrier device 170 puts the base substrate 10A within the dryingdevice 150G. Then, the filter layer 111FG is obtained on the dischargedportions 18G by completely drying the color filter material 111G on thedischarged portions 18G.

Next, the carrier device 170 puts the base substrate 10A on the stage106 of the discharging device 100B. Then, as shown in FIG. 14( b), thedischarging device 100B discharges the color filter material 111B fromthe discharging member 127 in the head 114 so as to form the layer ofthe color filter material 111B on all the discharged portions 18B. Amethod in which the discharging device 100B discharges the color filtermaterial 111B is the same as the way described above with reference toFIGS. 10, 11 and 12. After the layer of the color filter material 111Bis formed on all the discharged portions 18B of the base substrate 10A,the carrier device 170 puts the base substrate 10A within the dryingdevice 150B. Then, the filter layer 111FB is obtained on the dischargedportions 18B by completely drying the color filter material 111B on thedischarged portions 18B.

As mentioned above, the transmissive part 28 is approximately theelliptical shape as shown in detail in FIG. 21( b). More particularly,the transmissive part 28 is approximately the elliptical shape (a trackshape) which is consisted of a pair of straight lines and a pair ofsemicircles. Because the transmissive part 28 does not have any cornerswhich it is difficult to be filled with the color filter materials 111R,111G and 111B, the whole surface of the transmissive part 28 can befilled with the color filter materials 111R, 111G and 111B withoutleaving any unfilled parts. Therefore, when the color filter materials111R, 111G and 111B are dried, the transmissive parts 28 are coveredwith the filter layers 111FR, 111FG and 111FB without leaving any spacebetween.

In this exemplary embodiment, the bank 30 has the water-shedding qualityagainst the color filter materials 111R, 111G and 111B. Further, thewater-shedding quality of the black matrix 17 against the color filtermaterials 111R, 111G and 111B is lower than that of the bank 30 againstthe color filter materials 111R, 111G and 111B. The black matrix 17rather shows a lyophilic quality to the color filter materials 111R,111G and 111B. The reason for this is that the fluorinated polymer isblended in the bank 30. In contrast, the black matrix 17 does notcontain any fluorinated polymers. Generally, a surface of a resin thatcontains the fluorinated polymer shows a higher water-shedding qualityagainst a carrier fluid that is contained in the liquid color filtermaterials compared with a surface of a resin that does not contain thefluorinated polymer. In contrast, many resins that do not containfluorine show the lyophilic quality to the above-mentioned liquidmaterials.

According to this exemplary embodiment, since the bank 30 shows therelatively high water-shedding quality, the color filter materialsdroplets that have just arrived at the discharged portions 18R, 18G and18B flow out to the black matrix 17 without going beyond the bank 30 andwithout flowing out of the discharged portions 18R, 18G and 18B.

Further, since a layer that shows an intended water-shedding quality anda layer that shows an intended lyophilic quality are formed, a surfacequality modification process to give the black matrix 17 or the bank 30the water-shedding quality or the lyophilic quality is not necessary.For example, a plasma treatment and an oxygen plasma treatment usingtetrafluoromethane as a treatment gas are not necessary to be performed.

Next, the carrier device 170 puts the base substrate 10A within the oven160. Then, the filter layers 111FR, 111FG and 111FB are heated again(post-bake) in the oven 160.

Next, the carrier device 170 puts the base substrate 10A on the stage106 of the discharging device 100C. The discharging device 100Cdischarges the liquid material so as to form the planarizing layer 34covering the filter layers 111FR, 111FG and 111FB and the bank 30. Afterthe planarizing layer 34 that covers the filter layers 111FR, 111FG and111FB and the bank 30 is formed, the carrier device 170 puts the basesubstrate 10A within the oven 150C. Then the planarizing layer 34 iscompletely dried in the oven 150C, and then the curing device 165 heatsthe planarizing layer 34 and it gets hardened completely.

Then, the plurality of electrodes 36 are formed on the planarizing layer34 and the alignment film 38A is formed to cover the plurality ofelectrodes 36 and the planarizing layer 34. Accordingly, the basesubstrate 10A becomes the color filter substrate 10 as shown in FIG. 14(d).

Next, the color filter substrate 10 and the counter substrate 12 that ismade separately are sealed together in such way that the alignment film38A opposes the alignment film 38B interposing the spacers therebetween.Then, a space between the two alignment films is filled with a liquidcrystal material. After that, the polarization plate 20A and thepolarization plate 20B are provided, and the light source member 16 isalso provided. Finally, the liquid crystal display device 11 isobtained.

Structures of a liquid crystal display device 51 of a second exemplaryembodiment is substantially the same as those of the liquid crystaldisplay device 11 of the first exemplary embodiment except the colorfilter substrate 10 in the liquid crystal display device 11 of the firstexemplary embodiment is replaced by a color filter substrate 50. In FIG.15, the same components or elements as those described in the firstexemplary embodiment are given the identical numerals and explanationsthat are overlaps with those of the first exemplary embodiment areomitted.

The liquid crystal display device 51 as shown in FIG. 15 has thepolarization plate 20A, the polarization plate 20B, the color filtersubstrate 50, the counter substrate 12, the liquid crystal layer 14 andthe light source member 16. The liquid crystal layer 14 is placedbetween the color filter substrate 50 and the counter substrate 12. Thecolor filter substrate 50 is placed between the liquid crystal layer 14and the light source member 16. The color filter substrate 50, theliquid crystal layer 14 and the counter substrate 12 are located betweenthe polarization plate 20A and the polarization plate 20B.

The color filter substrate 50 can include a light transmittablesubstrate 72, a resin scattering layer 71, a reflective part 66, atransmissive part 68, an overcoat layer 65 and filter layers 211FR,211FG and 211FB that are provided in the plural number. The color filtersubstrate 50 also includes a black matrix 57, a bank 70, a planarizinglayer 74, the light transmittable electrode 36 that is provided in theplural number and the alignment film 38A. In this embodiment, thesubstrate 72 is located between the polarization plate 20A and thereflective part 66 or the transmissive part 68.

The resin scattering layer 71 is provided to cover the substrate 72.Further the reflective part 66 and the transmissive part 68 locate onthe resin scattering layer 71. Both the reflective part 66 and thetransmissive part 68 are placed in an area corresponding to each offilter layers 211FR, 211FG and 211FB. In this exemplary embodiment, thereflective part 66 and the transmissive part 68 are the aluminum filmand its opening part, respectively.

A plane view shape of the transmissive part 68 is formed to beapproximately the elliptical shape as shown in FIG. 21( b). Moreparticularly, the transmissive part 68 is approximately the ellipticalshape (the track shape) which is consisted of a pair of straight linesand a pair of semicircles. The track shape can be any shape as long asit is suitable to a plane view shape of an opening 57A that is definedby a shape of the black matrix 57. For example, it can be a circularform in which the pair of straight lines is omitted or a track shapethat is consisted of two pairs of straight lines and two pairs ofcircular arc as long as the plane view shape of the opening 57A is closeto square.

An irregular concavity and convexity is formed on the resin scatteringlayer 71. Consequently, a reflecting surface of the reflective part 66formed on the resin scattering layer 71 also has the irregular concavityand convexity. The reflective part 66 has a function of reflecting lightto a random direction because the reflecting surface has the irregularconcavity and convexity.

The overcoat layer 65 is located on the reflective part 66. The overcoatlayer 65 is patterned to be the same form as that of the reflective part66. One purpose of providing the overcoat layer 65 is to lower a colorpurity of a reflected light.

The black matrix 57 is located on a part of the overcoat layer 65. Theblack matrix 57 has an opening 57A that is provided in the pluralnumber. To be more specific, the black matrix 57 is a light shieldingpart that has a shape defining the opening 57A. A plurality of theopenings 57A are provided in matrix and each opening 57A corresponds tothe pixel region G. The black matrix 57 is an example of the first layerof the invention.

Each of the filter layers 211FR, 211FG and 211FB corresponds to one ofthe three colors. In particular, the filter layer 211FR corresponds tored, the filter layer 211FG corresponds to green and the filter layer211FB corresponds to blue. Each of the filter layers 211FR, 211FG and211FB is located each of openings 57A respectively.

The bank 70 is formed on the black matrix 57. A planar shape of the bank70 is the same planar shape of the black matrix 57. As described indetail later, a water-shedding quality of the bank 70 against the liquidcolor filter material for forming the filter layers 211FR, 211FG and211FB is higher than that of the black matrix 17 against the colorfilter material. The bank 70 is an example of the second layer of theinvention.

The planarizing layer 74 is located to cover the filter layers 211FR,211FG and 211FB and the bank 70. To be more specific, the planarizinglayer 74 covers a step formed by the filter layers 211FR, 211FG and211FB and the bank 70 so as to obtain a substantially flat surface. Theplurality of electrodes 36 is located on the planarizing layer 74. Eachelectrode 36 has the stripe shape that extends in the Y-axis direction(direction perpendicular to the page of FIG. 15( a)) and the electroderuns parallel each other. The alignment film 38A is placed to cover theplurality of electrodes 36 and the planarizing layer 74, and the rubbingtreatment in a certain direction is performed.

As described above, in the color filter substrate 50, the reflectivepart 66 and the transmissive part 68 are located corresponding to eachof the filter layers 211FR, 211FG and 211FB. The liquid crystal displaydevice 51 having such color filter substrate 50 works as describedbelow.

When the back light (the light source member 16) is used, the light beamP from the back light travels through the polarization plate 20A and thesubstrate 72, and then passes through the transmissive part 68. Thelight beam passed through the transmissive part 68 enters into thefilter layers 211FR, 211FG and 211FB, and then a light beam that has acorrespondent wave length band is emitted from the filter layers 211FR,211FG and 211FB. The light beam (the colored light) form the filterlayers 211FR, 211FG and 211FB travels through the liquid crystal layer14 and the counter substrate 12, and then it is emitted from thepolarization plate 20B. At the emitting area of the polarization plate20B, an intensity of the light beam form the back light is modulatedaccording to the voltage applied between the electrode 36 and theelectrode 42.

On the other hand, when outside light is used, the light beam Sincluding the outside light travels through the polarization plate 20Band the counter substrate 12 and the liquid crystal layer 14, and entersinto the corresponding filter layers 211FR, 211FG and 211FB. Out of thelight beam traveled through the filter layers 211FR, 211FG and 211FB, alight beam that is reflected by the reflective part 66 passes againthrough the filter layers 211FR, 211FG and 211FB and then emitted as acorrespondent colored light. Each of colored light again travels throughthe liquid crystal layer 14 and the counter substrate 12, and then it isemitted from the polarization plate 20B. At the emitting area of thepolarization plate 20B, an intensity of the light beam including theoutside light is modulated according to the voltage applied between theelectrode 36 and the electrode 42.

With the above-described structure, a first light beam that enters forma first side of the black matrix 57 and travels through thecorrespondent filter layers 211FR, 211FG and 211FB is reflected to thefirst side by the reflective part 66. On the other hand, a second lightbeam that enters form a second side of the black matrix 57 is emitted tothe first side through the transmissive part 68 and the correspondentfilter layers 211FR, 211FG and 211FB. The first side of the black matrix57 means a side on which the planarizing layer 74 and the liquid crystallayer 14 are located. In contrast, the second side of the black matrix57 means a side on which the light source member 16 is located.

In this way, the liquid crystal display device 51 can display imagesmaking use of both the outside light and the light from the back light.The liquid crystal display device 51 having such function is called thetransflective display device.

The filter layers 211FR, 211FG and 211FB in the color filter substrate50 are formed by discharging the color filter material in the opening57A of the black matrix 57 with the ink-jet apparatus and the like.

In this exemplary embodiment, the color filter substrate 50 in which thefilter layers 211FR, 211FG and 211FB have not been provided yet may bereferred as a base substrate 50A. Also, in this exemplary embodiment,regions where each of filter layers 211FR, 211FG and 211FB are formedmay be referred as discharged portions 58R, 58G and 58B, respectively.According to this description, in this exemplary embodiment, eachconcave portion which is surrounded by the bank 70, the black matrix 57,the overcoat layer 65 and the transmissive part 68 corresponds to eachof the discharged portions 58R, 58G and 58B in the base substrate 50A.

Next, a manufacturing method for the liquid crystal display device 51 isdescribed.

Firstly, the reflective part 66 and the transmissive part 68 which isthe opening in the reflective part 66 are formed on a surface of a lighttransmittable material. More particularly, as shown in FIG. 16( a), aresin layer that is transmissible and made of polyimide and the like isformed on the light transmittable substrate 72 such as the glasssubstrate so as to almost cover the whole surface of the substrate bysputtering and the like. And then, a random concavity and convexity isgiven to a surface of the resin layer by a blast method. Consequentlythe resin scattering layer 71 is obtained. Here, the resin scatteringlayer 71 corresponds to the light transmittable member. Then, analuminum (Al) film is formed on the resin scattering layer 71 bysputtering and the like. After that, as shown in FIG. 16( b), the Alfilm is patterned so as to form the reflective part 66 and thetransmissive part 68 in each pixel region G. A remaining Al film on theresin scattering layer 71 is the reflective part 66 and an area wherethe Al film is removed is the transmissive part 68 after the patterning.In this way, the reflective part 66 and the transmissive part 68 areformed on the surface of the light transmittable material.

In this exemplary embodiment, as shown in detail in FIG. 21( b), a planeview shape of the transmissive part 68 is approximately the ellipticalshape when the transmissive part 68 is located on a virtual plane thatis parallel to the X-axis direction and the Y-axis direction. Moreparticularly, the transmissive part 68 is made to be approximately theelliptical shape (the track shape) which is consisted of the pair ofstraight lines and the pair of semicircles by patterning the Al film.The elliptical shape in this specification includes not only ellipse butalso the track shape and the oval shape. As mentioned before, the X-axisdirection and the Y-axis direction are the direction in which the nozzle118 moves relatively to the discharged portion.

Next, as shown in FIG. 16( b), the over coat layer can be applied so asto cover the reflective part 66 and the resin scattering layer 71 andpatterned to be the same shape as that of the reflective part 66. As aresult, the over coat layer 65 is obtained on the reflective part 66.

Next, a first material layer is formed so as to cover the reflectivepart 66 and the transmissive part 68. To be more specific, as shown inFIG. 16( d), the thermosetting acrylic resin in which black pigments arediffused (resin black) is applied in 3 μm thick to cover the overcoatlayer 65 and the substrate 72 that is exposed between two overcoatlayers 65 (in other words, between two reflective parts 66). As aresult, a resin black layer 57′ is formed. Here, the resin black layer57′ is an example of the above-mentioned first material layer.

Then, as shown in FIG. 16( b), a negative acrylic chemical amplificationtype photosensitive resist in which a fluorinated polymer is blended isapplied to cover the whole surface of the resin black layer 57′.

Consequently, a resist layer 70′ is obtained on the resin black layer57′. Here, the resist layer 70′ is an example of the above-mentionedsecond material layer.

Next, the resist layer 70′ and the resin black layer 57′ are patterned.To be more specific, the resist layer 70′ is exposed to the light hvthrough a photomask that has the light shielding part corresponding towhere the pixel region G is. Then, unexposed parts to the light hv, inother words, many parts of the resist layer 70′ and the resin blacklayer 57′ corresponding to where the plurality of the pixel regions Gare, are removed by etching with a certain etchant. In this way, theblack matrix 57 and the bank 70 and that have a shape surrounding thefilter layer which should be formed later are obtained at the same timeas shown in FIG. 16( e). Stated another way, the opening 57Acorresponding to the reflective part 66 and the transmissive part 68 isobtained.

Areas which are surrounded or defined by the black matrix 57, the bank70, the over coat layer 65 and the transmissive part 68 are thedischarged portions 58R, 58G and 58B. The bank 70 is lighttransmissible. Also, as mentioned above, the black matrix 57 is anexample of the first layer of the invention, and the bank 70 is anexample of the second layer of the invention.

In this manner, the area that is defined by the black matrix 57 and thebank 70 (in other words, the discharged portions 58R, 58G and 58B) isprovided on the base substrate 50A by forming the black matrix 57 andthe bank 70 located on the black matrix 57.

The base substrate 50A on which the discharged portions 58R, 58G and 58Bare formed is carried by the carrier device 170 (FIG. 1) to the stage106 of the discharging device 100R. Then, as shown in FIG. 17( a), thedischarging device 100R discharges the color filter material 211R fromthe head 114 so as to form the layer of the color filter material 211Ron all the discharged portions 58R. A method in which the dischargingdevice 100R discharges the color filter material 211R is the same as theway described above with reference to FIGS. 10, 11 and 12. After thelayer of the color filter material 211R is formed on all the dischargedportions 58R of the base substrate 50A, the carrier device 170 puts thebase substrate 50A within the drying device 150R. Then, the filter layer211FR is obtained on the discharged portions 58R by completely dryingthe color filter material 211R on the discharged portions 58R.

Next, the carrier device 170 puts the base substrate 50A on the stage106 of the discharging device 100G. Then, as shown in FIG. 17( b), thedischarging device 100G discharges the color filter material 211G fromthe head 114 so as to form the layer of the color filter material 211Gon all the discharged portions 58G. A method in which the dischargingdevice 100G discharges the color filter material 211G is the same as theway described above with reference to FIGS. 10, 11 and 12. After thelayer of the color filter material 211G is formed on all the dischargedportions 58G of the base substrate 50A, the carrier device 170 puts thebase substrate 50A within the drying device 150G. Then, the filter layer211FG is obtained on the discharged portions 58G by completely dryingthe color filter material 211G on the discharged portions 18G.

Next, the carrier device 170 puts the base substrate 50A on the stage106 of the discharging device 100B. Then, as shown in FIG. 17( c), thedischarging device 100B discharges the color filter material 211B fromthe head 114 so as to form the layer of the color filter material 211Bon all the discharged portions 58B. A method in which the dischargingdevice 100B discharges the color filter material 211B is the same as theway described above with reference to FIGS. 10, 11 and 12. After thelayer of the color filter material 211B is formed on all the dischargedportions 58B of the base substrate 10A, the carrier device 170 puts thebase substrate 50A within the drying device 150B. Then, the filter layer211FB is obtained on the discharged portions 58B by completely dryingthe color filter material 211B on the discharged portions 58B.

As mentioned above, the transmissive part 68 is approximately theelliptical shape as shown in detail in FIG. 21( b). More particularly,the transmissive part 68 is approximately the elliptical shape (thetrack shape) which is consisted of the pair of straight lines and thepair of semicircles. Because the transmissive part 68 does not have anycorners which it is difficult to be filled with the color filtermaterials 211R, 211G and 211B, the whole surface of the transmissivepart 68 can be filled with the color filter materials 211R, 211G and211B without leaving any unfilled parts. Therefore, when the colorfilter materials 211R, 211G and 211B are dried, the transmissive parts68 are covered with the filter layers 211FR, 211FG and 211FB withoutleaving any space between.

In this exemplary embodiment, the bank 70 has the water-shedding qualityagainst the color filter materials 211R, 211G and 211B. Further, thewater-shedding quality of the black matrix 57 against the color filtermaterials 211R, 211G and 211B is lower than that of the bank 70 againstthe color filter materials 211R, 211G and 211B. The black matrix 57rather shows the lyophilic quality to the color filter materials 211R,211G and 211B. The reason for this is that the fluorinated polymer isblended in the bank 70. In contrast, the black matrix 57 does notcontain any fluorinated polymers. Generally, the surface of the resinthat contains the fluorinated polymer shows a higher water-sheddingquality against the carrier fluid that is contained in the liquid colorfilter materials compared with the surface of the resin that does notcontain the fluorinated polymer. In contrast, many resins that do notcontain fluorine show the lyophilic quality to the above-mentionedliquid materials.

According to this embodiment, since the bank 70 shows the relativelyhigh water-shedding quality, the color filter materials droplets thathave just arrived at the discharged portions 58R, 58G and 58B flow outto the black matrix 57 without going beyond the bank 70 and withoutflowing out of the discharged portions 58R, 58G and 58B.

Further, since a layer that shows an intended water-shedding quality anda layer that shows an intended lyophilic quality are formed, a surfacequality modification process to give the black matrix 57 or the bank 70the water-shedding quality or the lyophilic quality is not necessary.For example, the plasma treatment and the oxygen plasma treatment usingtetrafluoromethane as a treatment gas are not necessary to be performed.

Next, the carrier device 170 puts the base substrate 50A within the oven160. Then, the filter layers 211FR, 211FG and 211FB are heated again(post-bake) in the oven 160.

Next, the carrier device 170 puts the base substrate 50A on the stage106 of the discharging device 100C. The discharging device 100Cdischarges the liquid material so as to form the planarizing layer 74covering the filter layers 211FR, 211FG and 211FB and the bank 70.

After the planarizing layer 74 that covers the filter layers 211FR,211FG and 211FB and the bank 70 is formed, the carrier device 170 putsthe base substrate 50A within the oven 150C. Then the planarizing layer74 is completely dried in the oven 150C, and then the curing device 165heats the planarizing layer 74, and it gets hardened completely.

Then, the plurality of electrodes 36 are formed on the planarizing layer74 and the alignment film 38A is formed to cover the plurality ofelectrodes 36 and the planarizing layer 74. Accordingly, the basesubstrate 50A becomes the color filter substrate 50 as shown in FIG. 17(d).

Next, the color filter substrate 10 and the counter substrate that ismade separately are sealed together in such way that the alignment film38A opposes the alignment film 38B interposing the spacers therebetween.Then, a space between the two alignment films is filled with a liquidcrystal material. After that, the polarization plate 20A and thepolarization plate 20B are provided, and the light source member 16 isalso provided. Finally, the liquid crystal display device 51 isobtained.

Examples of electronic equipment that includes the above-describedembodiments are described.

FIG. 18 is a perspective view showing an example of a cellular phone. Asshown in FIG. 18, a cellular phone 1000 has a liquid crystal displaymember 1001. Either the liquid crystal display device 11 or the liquidcrystal display device 51 can be applied as the liquid crystal displaymember 1001.

FIG. 19 is a perspective view showing an example of wristwatch typeelectronic equipment. In FIG. 19, a watch body 1100 has the liquidcrystal display member 1001. Either the liquid crystal display device 11or the liquid crystal display device 51 can be applied as the liquidcrystal display member 1001.

FIG. 20 is a perspective view showing an example of a portableinformation processor, such as a personal computer. In FIG. 20, aninformation processor 1200 has an input member 1202, such as a keyboard,a body of the information processor 1204 and a liquid crystal displayusing a liquid crystal display member 1206. Either the liquid crystaldisplay device 11 or the liquid crystal display device 51 can be appliedas the liquid crystal display member 1206.

Since the electronic equipment shown in FIG. 18 through 20 have theliquid crystal display member in which the above-described liquidcrystal display device is used, the electronic equipment having a liquidcrystal display member that has a high level visibility and a finecoloration both in the reflective mode and the transmissive mode.

In the first through third exemplary embodiments, the shape of thetransmissive part 28 and the shape of the transmissive part 68 areapproximately the elliptical shape. However, it should be understoodthat the shape of the transmissive part 28 and the shape of thetransmissive part 68 may be a rectangle as shown in FIG. 21( a). Even ifthe shape of the transmissive part 28 and the transmissive part 68 isrectangular, the step locating at the border between the reflective partand the transmissive part can be adequately covered with dischargeddroplets as long as the discharging the material to the transmissivepart 28 or 68 and the discharging the material to the reflective part 26or 66 are conducted in this order. However, when the approximatelyelliptical shape transmissive part and the discharging method to thetransmissive part are combined, certainty of covering the step willrise.

The color filter substrate of the above-described first and secondembodiment is applied to the liquid crystal display device. However, thecolor filter substrate of the first and second embodiment may be appliedto other display device than the liquid crystal display device. In thisspecification, the display device includes a plasma display device, aliquid crystal display device, an electro-luminescence display device, adisplay device using an electron emission element, such as a fieldemission display (FED) and a surface conduction electron emitter display(SED) and the like.

Even when the display device is not the transflective display device,the color purity can be improved with the above-described color filtersubstrate. Therefore, it is preferred that the color filter substratesof the first and second exemplary embodiment are provided in variousdisplay devices.

1. A color filter substrate, comprising: a reflective part; atransmissive part that is an opening of the reflective part and has agenerally elliptical shape; a first layer having a first pattern with ashape defining a gap, the first layer being a black matrix layer formedover a reflecting surface of the reflective part; a second layerdisposed on the first layer, the second layer being a bank layer havinga second pattern, the second pattern being substantially the same as thefirst pattern; a filter layer that is disposed in the opening and thatis formed to cover the reflective part and the transmissive part, thereflective part reflecting light through the filter layer, and thetransmissive part transmitting light through the filter layer; a lighttransmittable substrate formed below the reflective part; and a resinscattering layer formed between the light transmittable substrate andthe reflective part, irregular concavities and convexities being formedon the resin scattering layer in a first area that corresponds to thereflective part and in a second area that corresponds to thetransmissive part, the irregular concavities and convexities affectinglight that is transmitted through the transmissive part and the filterlayer, and a reflecting surface of the reflective part also having theirregular concavities and convexities.
 2. The color filter substrateaccording to claim 1, a surface of the reflective part being a lightscattering surface.
 3. The color filter substrate according to claim 1,a water-shedding quality of the second layer against a liquid colorfilter material of the filter layer being higher than that of the firstlayer.
 4. The color filter substrate according to claim 3, the firstlayer showing a lyophilic quality to the liquid color filter material.5. The color filter substrate according to claim 1, the second layerbeing a resist to pattern the first layer.
 6. The color filter substrateaccording to claim 5, the resist including a fluorinated polymer.
 7. Thecolor filter substrate according to claim 1, further comprising: anovercoat layer that is disposed on the reflective part, the filter layercovering the overcoat layer and the transmissive part.
 8. A displaydevice, comprising the color filter substrate according to claim
 1. 9.Electronic equipment, comprising the display device according to claim8.
 10. The color filter substrate according to claim 1, a water-sheddingquality of the bank layer is higher than that of the black matrix layer.11. A liquid crystal display device, comprising: a light source memberthat generates a light beam; a liquid crystal layer; and a color filtersubstrate that is disposed between the light source member and theliquid crystal layer, the color filter substrate including: a reflectivepart; a transmissive part that is an opening of the reflective part andhaving a generally elliptical shape; a first layer having a firstpattern with a shape defining a gap, the first layer being a blackmatrix layer formed over a reflecting surface of the reflective part; asecond layer disposed on the first layer, the second layer being a banklayer having a second pattern, the second pattern being substantiallythe same as the first pattern; a filter layer that is disposed in theopening and that is formed to cover the reflective part and thetransmissive part, the reflective part reflecting light through thefilter layer, and the transmissive part transmitting light through thefilter layer; a light transmittable substrate formed below thereflective part; and a resin scattering layer formed between the lighttransmittable substrate and the reflective part, irregular concavitiesand convexities being formed on the resin scattering layer in a firstarea that corresponds to the reflective part and in a second area thatcorresponds to the transmissive part, the irregular concavities andconvexities affecting light that is transmitted through the transmissivepart and the filter layer, and a reflecting surface of the reflectivepart also having the irregular concavities and convexities. 12.Electronic equipment, comprising the liquid crystal display deviceaccording to claim
 11. 13. The liquid crystal display device accordingto claim 11, a water-shedding quality of the bank layer is higher thanthat of the black matrix layer.
 14. The liquid crystal display deviceaccording to claim 11, a water-shedding quality of the bank layer ishigher than that of the black matrix layer.